Peelable cable jackets having designed microstructures and methods for making peelable cable jackets having designed microstructures

ABSTRACT

Coated conductors comprising a conductor and a peelable polymeric coating at least partially surrounding the conductor, where the peelable polymeric coating comprises from 1 to 8 microcapillaries which comprise a low-viscosity filler material. Also disclosed are methods for making such coated conductors.

REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Application No. 62/233,624, filed on Sep. 28, 2015.

FIELD

Various embodiments of the present invention relate to cable coatings and jackets having microcapillary structures which allow for ease of peeling.

INTRODUCTION

Cables often require access to their core for ease of connection and installation. Generally, cables are designed for maximum protection of the internal components, requiring the use of tough materials. As a result, tearing the cable coating to access such internal components during connection or installation is difficult. For instance, when connecting cables, a skilled installer must typically use sharp cutting tools to split open the jacket and then use special tools to access the cable's internal components. The costs of network installation and subsequent maintenance or cable replacement can be lowered by usage of cables in which the inner components are easily accessible for ease of connection. While some attempts have been made to provide cable jackets with easy access to internal components, such advancements often come at the expense of the jackets' mechanical properties.

SUMMARY

One embodiment is a coated conductor, comprising:

-   -   (a) a conductor; and     -   (b) a peelable polymeric coating surrounding at least a portion         of said conductor,     -   wherein said peelable polymeric coating comprises a polymeric         matrix material and in the range of from 1 to 8 microcapillaries         which extend substantially in the direction of elongation of         said peelable polymeric coating,     -   wherein said microcapillaries comprise a low-viscosity filler         material.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is made to the accompanying drawings in which:

FIG. 1 is a perspective view, partially in cross-section, of an extruder with a die assembly for manufacturing a microcapillary film;

FIG. 2A is a longitudinal-sectional view of a microcapillary film;

FIGS. 2B and 2C are cross-sectional views of a microcapillary film;

FIG. 2D is an elevated view of a microcapillary film;

FIG. 2E is a segment 2E of a longitudinal sectional view of the microcapillary film, as shown in FIG. 2B;

FIG. 2F is an exploded view of a microcapillary film;

FIG. 2G is a cross-sectional view of a microcapillary film particularly depicting a single-layer embodiment;

FIGS. 3A and 3B are schematic perspective views of various configurations of extruder assemblies including an annular die assembly for manufacturing coextruded multi-layer annular microcapillary products and air-filled multi-layer annular microcapillary products, respectively;

FIG. 4A is a schematic view of a microcapillary film having microcapillaries with a fluid therein;

FIG. 4B is a cross-sectional view of a coextruded microcapillary film;

FIG. 4C is a cross-sectional view of an inventive air-filled microcapillary film;

FIG. 5 is a schematic view of an annular microcapillary tubing extruded from a die assembly;

FIGS. 6A and 6B are perspective views of an annular microcapillary tubing;

FIGS. 7A-7D are partial cross-sectional, longitudinal cross-sectional, end, and detailed cross-sectional views, respectively, of an annular die assembly in an asymmetric flow configuration;

FIGS. 8A-8D are partial cross-sectional, longitudinal cross-sectional, end, and detailed cross-sectional views, respectively, of an annular die assembly in a symmetric flow configuration;

FIGS. 9A-9D are partial cross-sectional, longitudinal cross-sectional, end, and detailed cross-sectional views, respectively, of an annular die assembly in a symmetric flow configuration; and

FIG. 10 is a perspective view of a die insert for an annular die assembly.

DETAILED DESCRIPTION

The present disclosure relates to die assemblies and extruders for producing annular microcapillary products. Such annular microcapillary products may be used in fabricating wire and cable articles of manufacture, such as by forming at least a portion of a polymeric coating (e.g., a jacket) or a polymeric protective component surrounding a conductive core.

The die assembly includes an annular die insert positioned between manifolds and defining material flow channels therebetween for extruding layers of a thermoplastic material. The die insert has a tip having microcapillary flow channels on an outer surface for insertion of microcapillary material in microcapillaries between the extruded layers of thermoplastic material. The microcapillaries may contain a variety of materials, such as other thermoplastic materials or elastomeric materials, or may simply be void-space microcapillaries (i.e., containing a gas, such as air). The die assemblies for producing annular microcapillary products are a variation of die assemblies for producing microcapillary films, both described in detail, below.

Microcapillary Film Extruder

FIG. 1 depicts an example extruder (100) used to form a polymeric film (110) with microcapillaries (103). The extruder (100) includes a material housing (105), a material hopper (107), a screw (109), a die assembly (111) and electronics (115). The extruder (100) is shown partially in cross-section to reveal the screw (109) within the material housing (105). While a screw-type extruder is depicted, a variety of extruders (e.g., single screw, twin screw, etc.) may be used to perform the extrusion of the material through the extruder (100) and die assembly (111). One or more extruders may be used with one or more die assemblies. Electronics (115) may include, for example, controllers, processors, motors and other equipment used to operate the extruder.

Raw materials (e.g. thermoplastic materials) (117) are placed into the material hopper (107) and passed into the housing (105) for blending. The raw materials (117) are heated and blended by rotation of the screw (109) rotationally positioned in the housing (105) of the extruder (100). A motor (121) may be provided to drive the screw (109) or other driver to advance the raw materials (117). Heat and pressure are applied as schematically depicted from a heat source T and a pressure source P (e.g., the screw (109)), respectively, to the blended material to force the raw material (117) through the die assembly (111) as indicated by the arrow. The raw materials (117) are melted and conveyed through the extruder (100) and die assembly (111). The molten raw material (117) passes through the die assembly (111) and is formed into the desired shape and cross section (referred to herein as the ‘profile’). The die assembly (111) may be configured to extrude the molten raw material (117) into thin sheets of the polymeric film (110) as is described further herein.

Microcapillary Film

FIGS. 2A-2F depict various views of a multi-layer film (210) which may be produced, for example, by the extruder (100) and die assembly (111) of FIG. 1. As shown in FIGS. 2A-2F, the multi-layer film (210) is a microcapillary film. The multi-layer film (210) is depicted as being made up of multiple layers (250 a,b) of thermoplastic material. The film (210) also has channels (220) positioned between the layers (250 a,b).

The multi-layer film (210) may also have an elongate profile as shown in FIG. 2C. This profile is depicted as having a wider width W relative to its thickness T. The thickness T may be in the range of from 100 to 2,000 μm (e.g., from 250 to 2000 μm). The channels (220) may have a dimension φ (e.g., a width or diameter) in the range of from 50 to 500 μm (e.g., from 100 to 500 μm, or 250 to 500 μm), and have a spacing S between the channels (220) in the range of from 50 to 500 μm (e.g., from 100 to 500 μm, or 250 to 500 μm). Additionally, the selected dimensions may be proportionally defined. For example, the channel dimension φ may be a diameter of about 30% of thickness T.

As shown, layers (250 a,b) are made of a matrix thermoplastic material and channels (220) have a channel fluid (212) therein. The channel fluid may comprise, for example, various materials, such as air, gas, polymers, etc., as will be described further herein. Each layer (250 a,b) of the multi-layer film (210) may be made of various polymers, such as those described further herein. Each layer may be made of the same material or of a different material. While only two layers (250 a,b) are depicted, the multi-layer film (210) may have any number of layers.

It should be noted that when the same thermoplastic material is employed for the layers (250 a,b), then a single layer (250) can result in the final product, due to fusion of the two streams of the matrix layers comprised of the same polymer in a molten state merging shortly before exiting the die. This phenomenon is depicted in FIG. 2G.

Channels (220) may be positioned between one or more sets of layers (250 a,b) to define microcapillaries (252) therein. The channel fluid (212) may be provided in the channels (220). Various numbers of channels (220) may be provided as desired. The multiple layers may also have the same or different profiles (or cross-sections). The characteristics, such as shape of the layers (250 a,b) and/or channels (220) of the film (210), may be defined by the configuration of the die assembly used to extrude the matrix material as will be described more fully herein.

The microcapillary film (210) has a first end (214) and a second end (216). One or more channels (220) are disposed in parallel in the matrix (218) from the first end (214) to the second end (216). The one or more channels (220) can have a diameter of at least 250 μm, or in the range of from 250 to 1990 μm, from 250 to 990 μm, from 250 to 890 μm, from 250 to 790 μm, from 250 to 690 μm, or from 250 to 590 μm. The one or more channels (220) may have a cross sectional shape selected from the group consisting of circular, rectangular, oval, star, diamond, triangular, square, hexagonal, pentagonal, octagonal, the like, and combinations thereof.

The matrix (218) comprises one or more matrix thermoplastic materials. Such matrix thermoplastic materials include, but are not limited to, polyolefins (e.g., polyethylenes, polypropylenes, etc.); polyamides (e.g., nylon 6); polyvinylidene chloride; polyvinylidene fluoride; polycarbonate; polystyrene; polyethylene terephthalate; polyurethane; and polyester. Specific examples of matrix thermoplastic materials include those listed on pages 5 through 11 of PCT Published Application No. WO 2012/094315, titled “Microcapillary Films and Foams Containing Functional Filler Materials,” which are herein incorporated by reference.

The one or more channel fluids (212) may include a variety of fluids, such as air, other gases, or channel thermoplastic material. Channel thermoplastic materials include, but are not limited to, polyolefins (e.g., polyethylenes, polypropylenes, etc.); polyamides (e.g., nylon 6); polyvinylidene chloride; polyvinylidene fluoride; polycarbonate; polystyrene; polyethylene terephthalate; polyurethane; and polyester. As with the matrix (218) materials discussed above, specific examples of thermoplastic materials suitable for use as channel fluids (212) include those listed on pages 5 through 11 of PCT Published Application No. WO 2012/094315.

Annular Microcapillary Product Extruder Assemblies

FIGS. 3A and 3B depict example extruder assemblies (300 a,b) used to form a multi-layer, annular microcapillary product (310 a,b) having microcapillaries (303). The extruder assemblies (300 a,b) may be similar to the extruder (100) of FIG. 1, except that the extruder assemblies (300 a,b) include multiple extruders (100 a,b,c), with combined annular microcapillary co-extrusion die assemblies (311 a,b) operatively connected thereto. The annular die assemblies (311 a,b) have die inserts (353) configured to extrude annular microcapillary products, such as film (310) as shown in FIGS. 4A-4C, tubing (310 a) as shown in FIGS. 5, 6A, and 6B, and/or molded shapes (310 b), as shown in FIG. 3B.

FIG. 3A depicts a first configuration of an extruder assembly (300 a) with three extruders (100 a,b,c) operatively connected to the combined annular microcapillary co-extrusion die assembly (311 a). In an example, two of the three extruders may be matrix extruders (100 a,b) used to supply thermoplastic material (e.g., polymer) (117) to the die assembly (311 a) to form layers of the annular microcapillary product (310 a). A third of the extruders may be a microcapillary (or core layer) extruder (100 c) to provide a microcapillary material, such as a thermoplastic material (e.g., polymer melt) (117), into the microcapillaries (303) to form a microcapillary phase (or core layer) therein.

The die insert (353) is provided in the die assembly (311 a) to combine the thermoplastic material (117) from the extruders (100 a,b,c) into the annular microcapillary product (310 a). As shown in FIG. 3A, the annular microcapillary product may be a blown tubing (310 a) extruded upwardly through the die insert (353) and out the die assembly (311 a). Annular fluid (312 a) from a fluid source (319 a) may be passed through the annular microcapillary product (310 a) to shape the annular microcapillary tubing (310 a) during extrusion as shown in FIG. 3A, or be provided with a molder (354) configured to produce an annular microcapillary product in the form of an annular microcapillary molding (or molded product), such as a bottle (310 b), shown in FIG. 3B.

FIG. 3B shows a second configuration of an extruder assembly (300 b). The extruder assembly (300 b) is similar to the extruder assembly (300 a), except that the microcapillary extruder (100 c) has been replaced with a microcapillary fluid source (319 b). The extruders (100 a,b) extrude thermoplastic material (as in the example of FIG. 3A) and the microcapillary fluid source (319 b) may emit microcapillary material in the form of a microcapillary fluid (312 b) through the die insert (353) of the die assembly (311 b). The two matrix extruders (100 a,b) emit thermoplastic layers, with the microcapillary fluid source (319 b) emitting microcapillary fluid (312 b) into the microcapillaries (303) therebetween to form the annular microcapillary product (310 b). In this version, the annular die assembly (311 b) may form film or blown products as in FIG. 3A, or be provided with a molder (354) configured to produce an annular microcapillary product in the form of an annular microcapillary molding, such as a bottle, (310 b).

While FIGS. 3A and 3B show each extruder (100 a,b,c) as having a separate material housing (105), material hopper (107), screw (109), electronics (115), motor (121), part or all of the extruders (100) may be combined. For example, the extruders (100 a,b,c) may each have their own hopper (107), and share certain components, such as electronics (115) and die assembly (311 a,b). In some cases, the fluid sources (319 a,b) may be the same fluid source providing the same fluid (312 a,b), such as air.

The die assemblies (311 a,b) may be operatively connected to the extruders (100 a,b,c) in a desired orientation, such as a vertical upright position as shown in FIG. 3A, a vertical downward position as shown in FIG. 3B, or a horizontal position as shown in FIG. 1. One or more extruders may be used to provide the polymeric matrix material that forms the layers and one or more material sources, such as extruder (100 c) and/or microcapillary fluid source (319 b), may be used to provide the microcapillary material. Additionally, as described in more detail below, the die assemblies may be configured in a crosshead position for co-extrusion with a conductive core.

Annular Microcapillary Products

FIGS. 4A-4C depict various views of an annular microcapillary product which may be in the form of a film (310, 310′) produced, for example, by the extruders (300 a,b) and die assemblies (311 a,b) of FIGS. 3A and/or 3B. As shown in FIGS. 4A and 4B, the annular microcapillary product (310) may be similar to the film (210), except that the annular microcapillary product (310) is formed from the annular die assemblies (311 a,b) into polymeric matrix layers (450 a,b) with microcapillaries (303, 303′) therein. The polymeric matrix layers (450 a,b) collectively form a polymeric matrix (418) of the annular microcapillary product (310). The layers (450 a,b) have parallel, linear channels (320) defining microcapillaries (303) therein.

As shown in FIGS. 4B and 4C, the annular microcapillary product (310, 310′) may be extruded with various microcapillary material (117) or microcapillary fluid (312 b) therein. The microcapillaries may be formed in channels (320, 320′) with various cross-sectional shapes. In the example of FIG. 4B, the channels (320) have an arcuate cross-section defining the microcapillaries (303) with the microcapillary material (117) therein. The microcapillary material (117) is in the channels (320) between the matrix layers (450 a,b) that form the polymeric matrix (418). The microcapillary material (117) forms a core layer between the polymeric matrix layers (450 a,b).

In the example of FIG. 4C, the channels (320′) have an elliptical cross-section defining microcapillaries (303′) with the microcapillary material (312 b) therein. The microcapillary material (312 b) is depicted as fluid (e.g., air) in the channels (320′) between the layers (450 a,b) that form the polymeric matrix (418).

It should be noted that, as with the films described above, the annular microcapillary product can take the form of a single-layer product when the same matrix material is employed for the layers (450 a,b). This is due to the fusion of the two streams of the matrix layers in a molten state merging shortly before exiting the die.

The materials used to form the annular microcapillary products as described herein may be selected for a given application. For example, the material may be a plastic, such as a thermoplastic or thermoset material. When a thermoplastic material is employed, the thermoplastic material (117) forming the polymeric matrix (418) and/or the microcapillary material (117) may be selected from those materials useful in forming the film (210) as described above. Accordingly, the annular microcapillary products may be made of various materials, such as polyolefins (e.g., polyethylene or polypropylene). For example, in FIGS. 4A and 4B, the polymeric matrix (418) may be a low-density polyethylene and the microcapillary material (117) may be polypropylene. As another example, in FIG. 4C the polymeric matrix (418) can be made of low-density polyethylene with air as the microcapillary material (312 b).

Referring to FIG. 5, the fluid source (319 a) may pass annular fluid (e.g., air) (312 a) through the annular microcapillary product (310 a) to support the tubular shape during extrusion. The die assembly (311 a) may form the multi-layer, annular microcapillary product (310 a,310 a′) into a tubular shape as shown in FIGS. 6A-6B.

As also shown by FIGS. 6A and 6B, the thermoplastic materials forming portions of the multi-layer, annular microcapillary product (310 a,310 a′) may be varied. In the example shown in FIGS. 4A, 4B, and 6A, the layers (450 a,b) forming polymeric matrix (418) may have a different material from the microcapillary material (117) in the microcapillaries (303) as schematically indicated by the black channels (320) and white polymeric matrix (418). In another example, as shown in FIG. 6B, the layers (450 a,b) forming a polymeric matrix (418) and the material in microcapillaries (303) may be made of the same material, such as low-density polyethylene, such that the polymeric matrix (418) and the channels (320) are both depicted as black.

Die Assemblies for Annular Microcapillary Products

FIGS. 7A-9D depict example configurations of die assemblies (711,811,911) usable as the die assembly (311). While FIGS. 7A-9D show examples of possible die assembly configurations, combinations and/or variations of the various examples may be used to provide the desired multi-layer, annular microcapillary product, such as those shown in the examples of FIGS. 4A-6B.

FIGS. 7A-7D depict partial cross-sectional, longitudinal cross-sectional, end, and detailed cross-sectional views, respectively, of the die assembly (711). FIGS. 8A-8D depict partial cross-sectional, longitudinal cross-sectional, end, and detailed cross-sectional views, respectively, of the die assembly (811). FIGS. 9A-9D depict partial cross-sectional, longitudinal cross-sectional, end, and detailed cross-sectional views, respectively, of the die assembly (911). The die assemblies (711, 811) may be used, for example, with the extruder assembly (300 a) of FIG. 3A and the die assembly (911) may be used, for example, with the extruder assembly (300 b) of FIG. 3B to form annular microcapillary products, such as those described herein.

As shown in FIGS. 7A-7D, the die assembly (711) includes a shell (758), an inner manifold (760), an outer manifold (762), a cone (764), and a die insert (768). The shell (758) is a tubular member shaped to receive the outer manifold (762). The outer manifold (762), die insert (768), and the inner manifold (760) are each flange shaped members stacked and concentrically received within the shell (758). While an inner manifold (760) and an outer manifold (762) are depicted, one or more inner and/or outer manifolds or other devices capable of providing flow channels for forming layers of the polymeric matrix may be provided.

The die insert (768) is positioned between the outer manifold (762) and the inner manifold (760). The inner manifold (760) has the cone (764) at an end thereof extending through the die insert (768) and the outer manifold (762) and into the shell (758). The die assembly (711) may be provided with connectors, such as bolts (not shown), to connect portions of the die assembly (711).

Referring now to FIG. 7B, annular matrix channels (774 a,b) are defined between the shell (758) and the outer manifold (762) and between the die insert (768) and the inner manifold (760), respectively. The thermoplastic material (117) is depicted passing through the matrix channels (774 a,b) as indicated by the arrows to form the layers (450 a,b) of the multi-layer, annular microcapillary product (710). The annular microcapillary product (710) may be any of the annular microcapillary products described herein, such as (310 a,b).

A microcapillary channel (776) is also defined between the die insert (768) and the outer manifold (762). The microcapillary channel (776) may be coupled to the microcapillary material source for passing the microcapillary material (117,312 b) through the die assembly (711) and between the layers (450 a,b) to form the microcapillaries (303) therein. The fluid channel (778) extends through the inner manifold (760) and the cone (764). Annular fluid (312 a) from fluid source (319 a) flows through the fluid channel (778) and into the product (710 a,).

The die insert (768) may be positioned concentrically between the inner manifold (760) and the outer manifold (762) to provide uniform distribution of polymer melt flow through the die assembly (711). The die insert (762) may be provided with a distribution channel (781) along an outer surface thereof to facilitate the flow of the microcapillary material (117/312 b) therethrough.

The matrix channels (774 a,b) and the microcapillary channel (776) converge at convergence (779) and pass through an extrusion outlet (780) such that thermoplastic material flowing through matrix channels (774 a,b) forms layers (450 a,b) with microcapillary material (117/312 b) from microcapillary channel (776) therebetween. The outer manifold (762) and die insert (768) each terminate at an outer nose (777 a) and an insert nose (777 b), respectively. As shown in FIG. 7D, the outer nose (777 a) extends a distance A further toward the extrusion outlet (780) and/or a distance A further away from the extrusion outlet (780) than the nose (777 b).

The die assemblies (811, 911) of FIGS. 8A-9D may be similar to the die assembly (711) of FIGS. 7A-7D, except that a position of noses (777 a,b, 977 a,b) of the die insert (768, 968) relative to the outer manifold (762) may be varied. The position of the noses may be adjusted to define a flow pattern, such as asymmetric or symmetric therethrough. As shown in FIGS. 7A-7D, the die assembly (711) is in an asymmetric flow configuration with nose (777 b) of the die insert (768) positioned a distance A from the nose (777 a) of the outer manifold (762). As shown in FIGS. 8A-8D, the die assembly (811) is in the symmetric flow configuration with the noses (777 a,b) of the die insert (768) and the outer manifold (762) being flush.

FIGS. 9A-9D and 10 depict an annular die insert (968) provided with features to facilitate the creation of the channels (320), microcapillaries (303), and/or insertion of the microcapillary material (117/312 b) therein (see, e.g., FIGS. 4A-4B). The die insert (968) includes a base (982), a tubular manifold (984), and a tip (986). The base (982) is a ring shaped member that forms a flange extending from a support end of the annular microcapillary manifold (984). The base (982) is supportable between the inner manifold (760) and outer manifold (762). The outer manifold (762) has an extended nose (977 a) and the die insert (968) has an extended nose (977 b) positioned flush to each other to define a symmetric flow configuration through the die assembly (911).

The tip (986) is an annular member at a flow end of the tubular manifold (984). An inner surface of the tip (986) is inclined and shaped to receive an end of the cone (764). The tip (986) has a larger outer diameter than the annular microcapillary manifold (984) with an inclined shoulder (990) defined therebetween. An outer surface of the tip (986) has a plurality of linear, parallel microcapillary flow channels (992) therein for the passage of the microcapillary material (117/312 b) therethrough. The outer manifold 762 terminates in a sharp edge (983 a) along nose (977 a) and tip (986) terminates in a sharp edge (983 b) along nose (977 b).

The annular microcapillary manifold (984) is an annular member extending between the base (982) and the tip (986). The annular microcapillary manifold (984) is supportable between a tubular portion of the inner manifold (760) and the outer manifold (762). The annular microcapillary manifold (984) has a passage (988) to receive the inner manifold (760).

The distribution channel (781) may have a variety of configurations. As shown in FIGS. 9A-9D, an outer surface of the annular microcapillary manifold (984) has the distribution channel (781) therealong for the passage of material therethrough. The distribution channel (781) may be in fluid communication with the microcapillary material (117/312 b) via the microcapillary channel (776) as schematically depicted in FIG. 9B. The distribution channel (781) may be positioned about the die insert (968) to direct the microcapillary material around a circumference of the die insert (968). The die insert (968) and/or distribution channel (781) may be configured to facilitate a desired amount of flow of microcapillary material (117/312 b) through the die assembly. The distribution channel (781) defines a material flow path for the passage of the microcapillary material between the die insert (968) and the outer manifold (762).

A small gap may be formed between the die insert (968) and the outer manifold (762) that allows the microcapillary material (117/312 b) to leak out of the distribution channel (781) to distribute the microcapillary material (117/312 b) uniformly through the die assembly (911). The distribution channel (781) may be in the form of a cavity or channel extending a desired depth into the die insert (968) and/or the outer manifold (760). For example, as shown in FIGS. 7A-9D, the distribution channel (781) may be a space defined between the outer surface of the die insert (968) and the outer manifold (760). As shown in FIG. 10, the distribution channel (781, 1081) is a helical groove extending a distance along the outer surface of the tubular manifold (984). Part or all of the distribution channel (781, 1081) may be linear, curved, spiral, cross-head, and/or combinations thereof.

Coated Conductor

The above-described annular microcapillary products can be used to prepare coated conductors, such as a cable. “Cable” and “power cable” mean at least one conductor within a sheath, e.g., an insulation covering and/or a protective outer jacket. “Conductor” denotes one or more wire(s) or fiber(s) for conducting heat, light, and/or electricity. The conductor may be a single-wire/fiber or a multi-wire/fiber and may be in strand form or in tubular form. Non-limiting examples of suitable conductors include metals such as silver, gold, copper, carbon, and aluminum. The conductor may also be optical fiber made from either glass or plastic. “Wire” means a single strand of conductive metal, e.g., copper or aluminum, or a single strand of optical fiber. Typically, a cable is two or more wires or optical fibers bound together, often in a common insulation covering and/or protective jacket. The individual wires or fibers inside the sheath may be bare, covered or insulated. Combination cables may contain both electrical wires and optical fibers. When the cable is a power cable, the cable can be designed for low, medium, and/or high voltage applications. Typical cable designs are illustrated in U.S. Pat. Nos. 5,246,783, 6,496,629 and 6,714,707. When the cable is a telecommunication cable, the cable can be designed for telephone, local area network (LAN)/data, coaxial CATV, coaxial RF cable or a fiber optic cable.

The above-described annular microcapillary products can constitute at least one polymeric coating layer in a cable, which is elongated in the same direction of elongation as the conductor or conductive core of the cable. As such, the polymeric coating can surround at least a portion of the conductor. In surrounding the conductor, the polymeric coating can be either in direct contact with the conductor or can be in indirect contact with the conductor by being placed on one or more interceding layers between the conductor and the polymeric coating. The polymeric coating comprises a polymeric matrix material and a plurality of microcapillaries which extend substantially in the direction of elongation of the polymeric coating. In various embodiments, the microcapillaries can be radially placed around the polymeric coating. Additionally, the microcapillaries can be spaced apart equidistantly or substantially equidistantly relative to one another.

One or more of the above-described die assemblies for producing annular microcapillary products can be modified to permit a conductor to pass therethrough, thereby allowing the polymeric coating comprising a polymeric matrix material and a plurality of microcapillaries to be coextruded onto the conductor or an interceding layer. Such a configuration is commonly known in the art as a crosshead die (see, e.g., US 2008/0193755 A1, US 2014/0072728 A1, and US 2013/0264092 A1). Specifically, the inner manifold (760) and cone (764) in FIGS. 7A, 8A and 9A can be modified to create a wire- or conductor-passing hole. As one of ordinary skill in the art would recognize, all the parts close to the die exit can be modified such that the extrusion materials are able to coat onto a conductor (or interceding layer) traveling through the wire- or conductor-passing hole. An additional part with molding passage can be fabricated. Such modifications are within the capabilities of one having ordinary skill in the art.

In an exemplary microcapillary extrusion coating process, a conductor core through an extrusion coating equipment can be pulled by a retractor to continuously move through the wire-passing hole of the inner manifold (760) to go through the projection end and then pass through the molding passage of the outer die. While the conductor core is moving, the polymer melt is injected by pressure into the material-supplying passages, flows toward to the wiring coating passage, and then into the molding passage at the outlet to coat onto the outer surface of the conductor core which is passing through the molding passage. Subsequently, the coated conductor core continues to move through the molding passage to outside the die, and then it can be cooled and hardened.

In preparing the polymeric coating, any of the above-described polymers can be used as the polymeric matrix material. In various embodiments, the polymer employed as the polymeric matrix material can comprise an ethylene-based polymer. As used herein, “ethylene-based” polymers are polymers prepared from ethylene monomers as the primary (i.e., greater than 50 weight percent (“wt %”)) monomer component, though other co-monomers may also be employed. “Polymer” means a macromolecular compound prepared by reacting (i.e., polymerizing) monomers of the same or different type, and includes homopolymers and interpolymers. “Interpolymer” means a polymer prepared by the polymerization of at least two different monomer types. This generic term includes copolymers (usually employed to refer to polymers prepared from two different monomer types), and polymers prepared from more than two different monomer types (e.g., terpolymers (three different monomer types) and tetrapolymers (four different monomer types)).

In various embodiments, the ethylene-based polymer can be an ethylene homopolymer. As used herein, “homopolymer” denotes a polymer comprising repeating units derived from a single monomer type, but does not exclude residual amounts of other components used in preparing the homopolymer, such as chain transfer agents.

In an embodiment, the ethylene-based polymer can be an ethylene/alpha-olefin (“a olefin”) interpolymer having an α-olefin content of at least 1 wt %, at least 5 wt %, at least 10 wt %, at least 15 wt %, at least 20 wt %, or at least 25 wt % based on the entire interpolymer weight. These interpolymers can have an α-olefin content of less than 50 wt %, less than 45 wt %, less than 40 wt %, or less than 35 wt % based on the entire interpolymer weight. When an α-olefin is employed, the α-olefin can be a C₃₋₂₀ (i.e., having 3 to 20 carbon atoms) linear, branched or cyclic α-olefin. Examples of C₃₋₂₀ α-olefins include propene, 1 butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1 dodecene, 1 tetradecene, 1 hexadecene, and 1-octadecene. The α-olefins can also have a cyclic structure such as cyclohexane or cyclopentane, resulting in an α-olefin such as 3 cyclohexyl-1-propene (allyl cyclohexane) and vinyl cyclohexane. Illustrative ethylene/α-olefin interpolymers include ethylene/propylene, ethylene/1-butene, ethylene/1 hexene, ethylene/1 octene, ethylene/propylene/1-octene, ethylene/propylene/1-butene, and ethylene/1-butene/1 octene.

Ethylene-based polymers also include interpolymers of ethylene with one or more unsaturated acid or ester monomers, such as unsaturated carboxylic acids or alkyl (alkyl)acrylates. Such monomers include, but are not limited to, vinyl acetate, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, acrylic acid, and the like. Accordingly, ethylene-based polymers can include interpolymers such as poly(ethylene-co-methyl acrylate) (“EMA”), poly(ethylene-co-ethyl acrylate) (“EEA”), poly(ethylene-co-butyl acrylate) (“EBA”), and poly(ethylene-co-vinyl acetate) (“EVA”).

In various embodiments, the ethylene-based polymer can be used alone or in combination with one or more other types of ethylene-based polymers (e.g., a blend of two or more ethylene-based polymers that differ from one another by monomer composition and content, catalytic method of preparation, etc). If a blend of ethylene-based polymers is employed, the polymers can be blended by any in-reactor or post-reactor process.

In an embodiment, the ethylene-based polymer can be a low-density polyethylene (“LDPE”). LDPEs are generally highly branched ethylene homopolymers, and can be prepared via high pressure processes (i.e., HP-LDPE). LDPEs suitable for use herein can have a density ranging from 0.91 to 0.94 g/cm³. In various embodiments, the ethylene-based polymer is a high-pressure LDPE having a density of at least 0.915 g/cm³, but less than 0.94 g/cm³, or in the range of from 0.924 to 0.938 g/cm³. Polymer densities provided herein are determined according to ASTM International (“ASTM”) method D792. LDPEs suitable for use herein can have a melt index (I₂) of less than 20 g/10 min., or ranging from 0.1 to 10 g/10 min., from 0.5 to 5 g/10 min., from 1 to 3 g/10 min., or an 12 of 2 g/10 min. Melt indices provided herein are determined according to ASTM method D1238. Unless otherwise noted, melt indices are determined at 190° C. and 2.16 Kg (i.e., 12). Generally, LDPEs have a broad molecular weight distribution (“MWD”) resulting in a relatively high polydispersity index (“PDI;” ratio of weight-average molecular weight to number-average molecular weight).

In an embodiment, the ethylene-based polymer can be a linear-low-density polyethylene (“LLDPE”). LLDPEs are generally ethylene-based polymers having a heterogeneous distribution of comonomer (e.g., α-olefin monomer), and are characterized by short-chain branching. For example, LLDPEs can be copolymers of ethylene and α-olefin monomers, such as those described above. LLDPEs suitable for use herein can have a density ranging from 0.916 to 0.925 g/cm³. LLDPEs suitable for use herein can have a melt index (I₂) ranging from 1 to 20 g/10 min., or from 3 to 8 g/10 min.

In an embodiment, the ethylene-based polymer can be a very-low-density polyethylene (“VLDPE”). VLDPEs may also be known in the art as ultra-low-density polyethylenes, or ULDPEs. VLDPEs are generally ethylene-based polymers having a heterogeneous distribution of comonomer (e.g., α-olefin monomer), and are characterized by short-chain branching. For example, VLDPEs can be copolymers of ethylene and α-olefin monomers, such as one or more of those α-olefin monomers described above. VLDPEs suitable for use herein can have a density ranging from 0.87 to 0.915 g/cm³. VLDPEs suitable for use herein can have a melt index (I₂) ranging from 0.1 to 20 g/10 min., or from 0.3 to 5 g/10 min.

In an embodiment, the ethylene-based polymer can be a medium-density polyethylene (“MDPE”). MDPEs are ethylene-based polymers having densities generally ranging from 0.926 to 0.950 g/cm³. In various embodiments, the MDPE can have a density ranging from 0.930 to 0.949 g/cm³, from 0.940 to 0.949 g/cm³, or from 0.943 to 0.946 g/cm³. The MDPE can have a melt index (I₂) ranging from 0.1 g/10 min, or 0.2 g/10 min, or 0.3 g/10 min, or 0.4 g/10 min, up to 5.0 g/10 min, or 4.0 g/10 min, or, 3.0 g/10 min or 2.0 g/10 min, or 1.0 g/10 min.

In an embodiment, the ethylene-based polymer can be a high-density polyethylene (“HDPE”). HDPEs are ethylene-based polymers generally having densities greater than 0.940 g/cm³. In an embodiment, the HDPE has a density from 0.945 to 0.97 g/cm³, as determined according to ASTM D 792. The HDPE can have a peak melting temperature of at least 130° C., or from 132 to 134° C. The HDPE can have a melt index (I₂) ranging from 0.1 g/10 min, or 0.2 g/10 min, or 0.3 g/10 min, or 0.4 g/10 min, up to 5.0 g/10 min, or 4.0 g/10 min, or, 3.0 g/10 min or 2.0 g/10 min, or 1.0 g/10 min, or 0.5 g/10 min. Also, the HDPE can have a PDI in the range of from 1.0 to 30.0, or in the range of from 2.0 to 15.0, as determined by gel permeation chromatography.

In an embodiment, the ethylene-based polymer can comprise a combination of any two or more of the above-described ethylene-based polymers.

In an embodiment, the polymeric matrix material can comprise LDPE. In an embodiment, the polymeric matrix material is LDPE.

In an embodiment, the polymeric matrix material can comprise MDPE. In an embodiment, the polymeric matrix material is MDPE.

Production processes used for preparing ethylene-based polymers are wide, varied, and known in the art. Any conventional or hereafter discovered production process for producing ethylene-based polymers having the properties described above may be employed for preparing the ethylene-based polymers described herein. In general, polymerization can be accomplished at conditions known in the art for Ziegler-Natta or Kaminsky-Sinn type polymerization reactions, that is, at temperatures from 0 to 250° C., or 30 or 200° C., and pressures from atmospheric to 10,000 atmospheres (1,013 megaPascal (“MPa”)). In most polymerization reactions, the molar ratio of catalyst to polymerizable compounds employed is from 10-12:1 to 10 1:1, or from 10-9:1 to 10-5:1.

Examples of suitable commercially available ethylene-based polymers include, but are not limited to AXELERON™ GP C-0588 BK (LDPE), AXELERON™ FO 6548 BK (MDPE), AXELERON™ GP A-7530 NT (LLDPE), AXELERON™ GP G-6059 BK (LLDPE), AXELERON™ GP K-3479 BK (HDPE), AXELERON™ GP A-1310 NT (HDPE), and AXELERON™ FO B-6549 NT (MDPE), all of which are commercially available from The Dow Chemical Company, Midland, Mich., USA.

Polypropylene-based polymers, such as homopolymer, random copolymer, heterophasic copolymer, and high-crystalline homopolymer polypropylenes are commercially available from Braskem Corp.

In preparing the polymeric coating, any of the above-described materials can also be used as the microcapillary material.

In various embodiments, the microcapillary material is a gas. In one or more embodiments, the microcapillary material is air. In such embodiments, the microcapillaries define individual, discrete void spaces which are completely surrounded by the polymeric matrix material when viewed as a cross-section taken orthogonal to the direction of elongation of the microcapillaries.

In one or more embodiments, the microcapillary material can be an elastomeric microcapillary material. As known in the art, elastomers are materials which experience large reversible deformations under relatively low stress. In any embodiments where the microcapillaries are filled with a polymeric microcapillary material, the microcapillaries can define individual, discrete polymer-filled segments which are completely surrounded by the polymeric matrix material when viewed as a cross-section taken orthogonal to the direction of elongation of the microcapillaries.

In various embodiments, the elastomer can be an olefin elastomer. Olefin elastomers include both polyolefin homopolymers and interpolymers. Examples of the polyolefin interpolymers are ethylene/α-olefin interpolymers and propylene/α-olefin interpolymers. In such embodiments, the α-olefin can be any of those described above with respect to the ethylene-based polymer. Illustrative polyolefin copolymers include ethylene/propylene, ethylene/butene, ethylene/1-hexene, ethylene/1-octene, ethylene/styrene, and the like. Illustrative terpolymers include ethylene/propylene/1-octene, ethylene/propylene/butene, ethylene/butene/1-octene, and ethylene/butene/styrene. The copolymers can be random or blocky.

Olefin elastomers can also comprise one or more functional groups such as an unsaturated ester or acid or silane, and these elastomers (polyolefins) are well known and can be prepared by conventional high-pressure techniques. The unsaturated esters can be alkyl acrylates, alkyl methacrylates, or vinyl carboxylates. The alkyl groups can have 1 to 8 carbon atoms and preferably have 1 to 4 carbon atoms. The carboxylate groups can have 2 to 8 carbon atoms and preferably have 2 to 5 carbon atoms. The portion of the copolymer attributed to the ester comonomer can be in the range of 1 up to 50 percent by weight based on the weight of the copolymer. Examples of the acrylates and methacrylates are ethyl acrylate, methyl acrylate, methyl methacrylate, t-butyl acrylate, n-butyl acrylate, n-butyl methacrylate, and 2-ethylhexyl acrylate. Examples of the vinyl carboxylates are vinyl acetate, vinyl propionate, and vinyl butanoate. Examples of the unsaturated acids include acrylic acids or maleic acids. One example of an unsaturated silane is vinyl trialkoxysilane (e.g., vinyl trimethoxysilane and vinyl triethoxysilane).

More specific examples of the olefin elastomers useful in this invention include very-low-density polyethylene (“VLDPE”) (e.g., FLEXOMER™ ethylene/1-hexene polyethylene made by The Dow Chemical Company), homogeneously branched, linear ethylene/α-olefin copolymers (e.g. TAFMER™ by Mitsui Petrochemicals Company Limited and EXACT™ by Exxon Chemical Company), and homogeneously branched, substantially linear ethylene/α-olefin polymers (e.g., AFFINITY™ and ENGAGE™ polyethylene available from The Dow Chemical Company).

The olefin elastomers useful herein also include propylene, butene, and other alkene-based copolymers, e.g., copolymers comprising a majority of units derived from propylene and a minority of units derived from another α-olefin (including ethylene). Exemplary propylene polymers useful herein include VERSIFY™ polymers available from The Dow Chemical Company, and VISTAMAXX™ polymers available from ExxonMobil Chemical Company.

Olefin elastomers can also include ethylene-propylene-diene monomer (“EPDM”) elastomers and chlorinated polyethylenes (“CPE”). Commercial examples of suitable EPDMs include NORDEL™ EPDMs, available from The Dow Chemical Company. Commercial examples of suitable CPEs include TYRIN™ CPEs, available from The Dow Chemical Company.

Olefin elastomers, particularly ethylene elastomers, can have a density of less than 0.91 g/cm³ or less than 0.90 g/cm³. Ethylene copolymers typically have a density greater than 0.85 g/cm³ or greater than 0.86, g/cm³. Olefin elastomers can have a melt index (I₂) greater than 0.10 g/10 min., or greater than 1 g/10 min. Olefin elastomers can have a melt index of less than 500 g/10 min. or less than 100 g/10 min.

Other suitable olefin elastomers include olefin block copolymers (such as those commercially available under the trade name INFUSE™ from The Dow Chemical Company, Midland, Mich., USA), mesophase-separated olefin multi-block interpolymers (such as described in U.S. Pat. No. 7,947,793), and olefin block composites (such as described in U.S. Patent Application Publication No. 2008/0269412, published on Oct. 30, 2008).

In various embodiments, the elastomer useful as the microcapillary material can be a non-olefin elastomer. Non-olefin elastomers useful herein include silicone and urethane elastomers, styrene-butadiene rubber (“SBR”), nitrile rubber, chloroprene, fluoroelastomers, perfluoroelastomers, polyether block amides and chlorosulfonated polyethylene. Silicone elastomers are polyorganosiloxanes typically having an average unit formula R_(a)SiO_((4-a)/2) which may have a linear or partially-branched structure, but is preferably linear. Each R may be the same or different. R is a substituted or non-substituted monovalent hydrocarbyl group which may be, for example, an alkyl group, such as methyl, ethyl, propyl, butyl, and octyl groups; aryl groups such as phenyl and tolyl groups; aralkyl groups; alkenyl groups, for example, vinyl, allyl, butenyl, hexenyl, and heptenyl groups; and halogenated alkyl groups, for example chloropropyl and 3,3,3-trifluoropropyl groups. The polyorganosiloxane may be terminated by any of the above groups or with hydroxyl groups. When R is an alkenyl group the alkenyl group is preferably a vinyl group or hexenyl group. Indeed alkenyl groups may be present in the polyorganosiloxane on terminal groups and/or polymer side chains.

Representative silicone rubbers or polyorganosiloxanes include, but are not limited to, dimethylvinylsiloxy-terminated polydimethylsiloxane, trimethylsiloxy-terminated polydimethylsiloxane, trimethylsiloxy-terminated copolymer of methylvinylsiloxane and dimethylsiloxane, dimethylvinylsiloxy-terminated copolymer of methylvinylsiloxane and dimethylsiloxane, dimethylhydroxysiloxy-terminated polydimethylsiloxane, dimethylhydroxysiloxy-terminated copolymer of methylvinylsiloxane and dimethylsiloxane, methylvinylhydroxysiloxy-terminated copolymer of methylvinylsiloxane and dimethylsiloxane, dimethylhexenylsiloxy-terminated polydimethylsiloxane, trimethylsiloxy-terminated copolymer of methylhexenylsiloxane and dimethylsiloxane, dimethylhexenylsiloxy-terminated copolymer of methylhexenylsiloxane and dimethylsiloxane, dimethylvinylsiloxy-terminated copolymer of methylphenylsiloxane and dimethylsiloxane, dimethylhexenylsiloxy-terminated copolymer of methylphenylsiloxane and dimethylsiloxane, dimethylvinylsiloxy-terminated copolymer of methyl(3,3,3-trifluoropropyl)siloxane and dimethylsiloxane, and dimethylhexenylsiloxy-terminated copolymer of methyl(3,3,3-trifluoropropyl)siloxane and dimethylsiloxane.

Urethane elastomers are prepared from reactive polymers such as polyethers and polyesters and isocyanate functional organic compounds. One typical example is the reaction product of a dihydroxy functional polyether and/or a trihydroxy functional polyether with toluene diisocyanate such that all of the hydroxy is reacted to form urethane linkages leaving isocyanate groups for further reaction. This type of reaction product is termed a prepolymer which may cure by itself on exposure to moisture or by the stoichiometric addition of polycarbinols or other polyfunctional reactive materials which react with isocyanates. The urethane elastomers are commercially prepared having various ratios of isocyanate compounds and polyethers or polyesters. The most common urethane elastomers are those containing hydroxyl functional polyethers or polyesters and low molecular weight polyfunctional, polymeric isocyanates. Another common material for use with hydroxyl functional polyethers and polyesters is toluene diisocyanate.

Nonlimiting examples of suitable urethane rubbers include the PELLETHANE™ thermoplastic polyurethane elastomers available from the Lubrizol Corporation; ESTANE™ thermoplastic polyurethanes, TECOFLEX™ thermoplastic polyurethanes, CARBOTHANE™ thermoplastic polyurethanes, TECOPHILIC™ thermoplastic polyurethanes, TECOPLAST™ thermoplastic polyurethanes, and TECOTHANE™ thermoplastic polyurethanes, all available from Noveon; ELASTOLLAN™ thermoplastic polyurethanes and other thermoplastic polyurethanes available from BASF; and additional thermoplastic polyurethane materials available from Bayer, Huntsman, Lubrizol Corporation, Merquinsa and other suppliers. Preferred urethane rubbers are those so-called “millable” urethanes such as MILLATHANE™ grades from TSI Industries.

Additional information on such urethane materials can be found in Golding, Polymers and Resins, Van Nostrande, 1959, pages 325 et seq. and Saunders and Frisch, Polyurethanes, Chemistry and Technology, Part II, Interscience Publishers, 1964, among others.

Suitable commercially available elastomers for use as the microcapillary material include, but are not limited to, ENGAGE™ polyolefin elastomers available from The Dow Chemical Company, Midland, Mich., USA. A specific example of such an elastomer is ENGAGE™ 8200, which is an ethylene/octene copolymer having a melt index (I₂) of 5.0 and a density of 0.870 g/cm³.

In embodiments where an elastomer microcapillary material is employed, it may be desirable for the matrix material to have higher toughness, abrasion resistance, density, and/or flexural modulus relative to the elastomer. This combination affords a polymeric coating having a tough outer layer but with increased flexibility compared to a coating formed completely of the same matrix material. For example, in various embodiments, the polymeric coating can have one or more of the above-described elastomers as the microcapillary material with an ethylene-based polymer, a polyamide (e.g., nylon 6), polybutylene terephthalate (“PBT”), polyethylene terephthalate (“PET”), a polycarbonate, or combinations of two or more thereof as the polymeric matrix material. In various embodiments, the polymeric coating can comprise an olefin elastomer as the microcapillary material and the polymeric matrix material can be selected from the group consisting of HDPE, MDPE, LLDPE, LDPE, a polyamide, PBT, PET, a polycarbonate, or combinations of two or more thereof. In one or more embodiments, the microcapillary material can comprise an ethylene/octene copolymer olefin elastomer and the polymeric matrix material can comprise MDPE.

The above-described polymeric matrix material, microcapillary material, or both can contain one or more additives, such as those typically used in preparing cable coatings. For example, the polymeric matrix material, microcapillary material, or both can optionally contain a non-conductive carbon black commonly used in cable jackets. In various embodiments, the amount of a carbon black in the composition can be greater than zero (>0), typically from 1, more typically from 2, and up to 3 wt %, based on the total weight of the composition. In various embodiments, the composition can optionally include a conductive filler, such as a conductive carbon black, metal fibers, powders, or carbon nanotubes, at a high level for semiconductive applications.

Non-limiting examples of conventional carbon blacks include the grades described by ASTM N550, N472, N351, N110 and N660, Ketjen blacks, furnace blacks and acetylene blacks. Other non-limiting examples of suitable carbon blacks include those sold under the tradenames BLACK PEARLS®, CSX®, ELFTEX®, MOGUL®, MONARCH®, REGAL® and VULCAN®, available from Cabot.

The polymeric matrix material, microcapillary material, or both can optionally contain one or more additional additives, which are generally added in conventional amounts, either neat or as part of a masterbatch. Such additives include, but not limited to, flame retardants, processing aids, nucleating agents, foaming agents, crosslinking agents, fillers, pigments or colorants, coupling agents, antioxidants, ultraviolet stabilizers (including UV absorbers), tackifiers, scorch inhibitors, antistatic agents, plasticizers, lubricants, viscosity control agents, anti-blocking agents, surfactants, extender oils, acid scavengers, metal deactivators, vulcanizing agents, and the like.

In one or more embodiments, the polymeric matrix material, the microcapillary material, or both can be crosslinkable. Any suitable methods known in the art can be used to crosslink the matrix material and/or the microcapillary material. Such methods include, but are not limited to, peroxide crosslinking, silane functionalization for moisture crosslinking, UV crosslinking, or e-beam cure. Such crosslinking methods may require the inclusion of certain additives (e.g., peroxides), as known in the art.

In various embodiments, the polymeric matrix material, the microcapillary material, or both can contain one or more adhesion modifiers. Adhesion modifiers may be helpful in improving interfacial adhesion between the matrix material and the microcapillary material. Any known or hereafter discovered additive that improves adhesion between two polymeric materials may be used herein. Specific examples of suitable adhesion modifiers include, but are not limited to, maleic anhydride (“MAH”) grafted resins (e.g., MAH-grafted polyethylene, MAH-grafted ethylene vinyl acetate, MAH-grafted polypropylene), aminated polymers (e.g., amino-functionalized polyethylene), and the like, and combinations of two or more thereof. MAH-grafted resins are commercially available under the AMPLIFY™ GR trade name from The Dow Chemical Company (Midland, Mich., USA) and under the FUSABOND™ trade name from DuPont (Wilmington, Del., USA).

Non-limiting examples of flame retardants include, but are not limited to, aluminum hydroxide and magnesium hydroxide.

Non-limiting examples of processing aids include, but are not limited to, fatty amides such as stearamide, oleamide, erucamide, or N,N′ ethylene bis-stearamide; polyethylene wax; oxidized polyethylene wax; polymers of ethylene oxide; copolymers of ethylene oxide and propylene oxide; vegetable waxes; petroleum waxes; non-ionic surfactants; silicone fluids; polysiloxanes; and fluoroelastomers such as Viton® available from Dupon Performance Elastomers LLC, or Dynamar™ available from Dyneon LLC.

A non-limiting example of a nucleating agent include Hyperform® HPN-20E (1,2 cyclohexanedicarboxylic acid calcium salt with zinc stearate) from Milliken Chemicals, Spartanburg, S.C.

Non-limiting examples of fillers include, but are not limited to, various flame retardants, clays, precipitated silica and silicates, fumed silica, metal sulfides and sulfates such as molybdenum disulfide and barium sulfate, metal borates such as barium borate and zinc borate, metal anhydrides such as aluminum anhydride, ground minerals, and elastomeric polymers such as EPDM and EPR. If present, fillers are generally added in conventional amounts, e.g., from 5 wt % or less to 50 or more wt % based on the weight of the composition.

In various embodiments, the polymeric coating on the coated conductor can have a thickness ranging from 100 to 3,000 μm, from 500 to 3,000 μm, from 100 to 2,000 μm, from 100 to 1,000 μm, from 200 to 800 μm, from 200 to 600 μm, from 300 to 1,000 μm, from 300 to 900 μm, or from 300 to 700 μm. Additionally, the polymeric coating can have a thickness in the range of from 10 to 180 mils (254 μm to 4,572 μm).

Additionally, the average diameter of the microcapillaries in the polymeric coating can be at least 50 μm, at least 100 μm, or at least 250 μm. Furthermore, the microcapillaries in the polymeric coating can have an average diameter in the range of from 50 to 1,990 μm, from 50 to 990 μm, from 50 to 890 μm, from 100 to 790 μm, from 150 to 690 μm, or from 250 to 590 μm. It should be noted that, despite the use of the term diameter, the cross-section of the microcapillaries need not be round. Rather, they may take a variety of shapes, such as oblong as shown in FIGS. 4B and 4C. In such instances, the “diameter” shall be defined as the longest dimension of the cross-section of the microcapillary. This dimension is illustrated as λ in FIG. 4B. The “average” diameter shall be determined by taking three random cross-sections from a polymeric coating, measuring the diameter of each microcapillary therein, and determining the average of those measurements. The diameter measurement is conducted by cutting a cross section of the extruded article and observing under an optical microscope fitted with a scale to measure the diameter of the micro-capillary.

In one or more embodiments, the ratio of the thickness of the polymeric coating to the average diameter of the microcapillaries can be in the range of from 2:1 to 400:1

The spacing of the microcapillaries can vary depending on the desired properties to be achieved. Additionally, the spacing of the microcapillaries can be defined relative to the diameter of the microcapillaries. For instance, in various embodiments, the microcapillaries can be spaced apart a distance of less than 1 times the average diameter of the microcapillaries, and can be as high as 10 times the average diameter of the microcapillaries. In various embodiments, the microcapillaries can be spaced apart an average of 100 to 5,000 μm, an average of 200 to 1,000 μm, or an average of 100 to 500 μm. The measurement “spaced apart” shall be determined on an edge-to-edge basis, as illustrated by “s” in FIG. 2C.

In various embodiments, when the microcapillary material is an elastomer, the polymeric coating can have higher flexibility, especially at low temperature, and reduced density because of the presence of lower density elastomer in the microcapillary.

Peelable Coating

In one or more embodiments, a coated conductor is provided having a peelable polymeric coating. In such embodiments, the peelable polymeric coating comprises a polymeric matrix material and in the range of from 1 to 8 of the above-described microcapillaries which extend substantially in the direction of elongation of the peelable polymeric coating. In various embodiments, the peelable polymeric coating comprises from 1 to 6 microcapillaries, from 1 to 4 microcapillaries, or from 2 to 4 microcapillaries. In various embodiments, the peelable polymeric coating comprises two microcapillaries. In other embodiments, the peelable polymeric coating comprises three microcapillaries. In still other embodiments, the peelable polymeric coating comprises four microcapillaries.

In various embodiments, the microcapillaries can be spaced equidistantly or substantially equidistantly radially around the peelable polymeric coating. For instance, when viewing a cross-section of the peelable polymeric coating taken orthogonal to the direction of elongation of the microcapillaries, if the peelable polymeric coating contains only two microcapillaries, they can be spaced about 180° apart from one another; if the peelable polymeric coating contains three microcapillaries, they can be spaced about 120° apart from one another; or if the peelable polymeric coating contains four microcapillaries, they can be spaced about 90° apart from one another. In other embodiments, and regardless of their radial placement, when viewed as a cross section taken orthogonal to the direction of their elongation, the microcapillaries may be placed at different positions across the thickness of the coating, for examples in sets of two or more capillaries, on top or in close vicinity to one another and separated by a solid wall of the matrix material.

The microcapillaries of the peelable polymeric coating can (i) define individual, discrete void spaces; (ii) comprise an elastomeric polymer having a lower flexural modulus than the polymeric matrix material; (iii) comprise a non-polymeric, low-viscosity filler material capable of being pumped into the microcapillaries; or (iv) combinations of two or more of (i)-(iii).

Whether the microcapillaries are filled or void, the microcapillaries can be completely surrounded by the polymeric matrix material when viewed as a cross-section taken orthogonal to the direction of elongation of the microcapillaries. In various embodiments, the aggregate of the space defined by the microcapillaries when viewed in the cross-section can be less than 20 area percent (“area %”), less than 15 area %, less than 10 area %, or less than 5 area % of the total area of the peelable polymeric coating cross-section. In such embodiments, the aggregate of space defined by the microcapillaries when viewed in the cross-section can be at least 0.05 area %, at least 0.1 area %, at least 0.5 area %, at least 1 area %, or at least 2 area % of the total area of the peelable polymeric coating cross-section.

As noted above, in various embodiments, the microcapillaries can define individual, discrete void spaces. In such embodiments, the microcapillaries can be filled with a microcapillary fluid that is a gas a room temperature, such as air.

As noted above, in various embodiments, the microcapillaries can comprise an elastomeric polymer. In such embodiments, the elastomeric polymer has a lower flexural modulus than the polymeric matrix material, as described in greater detail below. Suitable elastomers include any of those described above, but may be limited due to the type of polymeric matrix material selected. In various embodiments, the elastomeric polymer can be selected from the group consisting of an olefin elastomer, a silicone elastomer, a urethane elastomer, an amorphous rubber, and combinations of two or more thereof.

As just noted, one or more embodiments of the present invention contemplate a peelable polymeric coating having a relatively high-modulus polymeric matrix material and a relatively low-modulus polymeric microcapillary material, where the flexural modulus of the polymeric matrix material is high relative to the polymeric microcapillary material and the flexural modulus of the polymeric microcapillary material is low relative to the polymeric matrix material. Generally, the high-modulus polymeric matrix material can have a flexural modulus of at least 300,000 psi, or in the range of from 300,000 to 800,000 psi, from 325,000 to 700,000 psi, or from 330,000 to 600,000 psi. By way of example, a typical flexural modulus for poly(p-phenylene sulfide) (“PPS”) is about 600,000 psi, for polyether-ether-ketone is about 590,000 psi, for polycarbonate is about 345,000 psi, for polyethylene terephthalate is about 400,000 psi, for polybutylene terephthalate is about 330,000 psi, and for nylon 6/6 is about 400,000 psi (all unfilled).

The high-modulus polymers are generally known as high-performance polymers exhibiting high heat resistance (as measured by the heat deflection temperature for example), excellent mechanical properties, as well as abrasion and chemical resistance properties. They are, however, typically higher density polymers, having densities generally greater than 1.3 g/cm³. In various embodiments, the high-modulus polymers of the polymeric matrix material can comprise polybutylene terephthalate (“PBT”), polyethylene terephthalate (“PET”), a polycarbonate, a polyamide (e.g., a nylon), polyether-ether-ketone (“PEEK), or combinations of two or more thereof. In an embodiment, the polymeric matrix material comprises PBT.

The low-modulus polymeric microcapillary material can have a flexural modulus of less than 250,000 psi, or in the range of from 100 to 250,000 psi, or from 500 to 200,000 psi. By way of example, a typical high-density polyethylene has a flexural modulus of about 200,000 psi, a typical low-density polyethylene has a flexural modulus of about 30,000 psi, a typical thermoplastic polyurethane has a flexural modulus of about 10,000 psi, and a typical polyolefin elastomer (e.g., ENGAGE™ 8402) has a flexural modulus of about 580 psi.

The low-modulus materials are generally characterized by high flexibility and excellent impact resistance, even at low temperatures. These resins can have a melt index ranging from less than 1.0 to greater than 1,000 g/10 minutes such as, for example, AFFINITY™ GA grades of olefin elastomer, commercially available from The Dow Chemical Company. These polyolefin elastomer resins can also have a density as low as 0.857 g/cm³ and a melting point as low as 38° C. such as ENGAGE™ 8842 also from The Dow Chemical Company.

In one or more embodiments, the polymeric microcapillary material can comprise any of the ethylene-based polymers described above (e.g., HDPE, LDPE, EEA, EVA); olefin elastomers (such as described above) and other ethylene copolymers such as AFFINITY™, ENGAGE™, and VERSIFY™ copolymers, commercially available from The Dow Chemical Company; olefin block copolymers (such as those commercially available under the trade name INFUSE™ from The Dow Chemical Company, Midland, Mich., USA), mesophase-separated olefin multi-block interpolymers (such as described in U.S. Pat. No. 7,947,793), olefin block composites (such as described in U.S. Patent Application Publication No. 2008/0269412, published on Oct. 30, 2008), or combinations of two or more thereof.

As noted above, in various embodiments, the microcapillaries can comprise a low-viscosity filler material capable of being pumped into the microcapillaries. In other words, such low-viscosity filler material can be incorporated into the microcapillaries following extrusion of the peelable polymeric coating; such fillers are not required to be co-extruded with the polymeric matrix material. This is in contrast with polymeric materials, such as the elastomers discussed above.

Suitable low-viscosity fillers include fluids with a broad range in viscosity, as shown in Table 1. As used herein, “low-viscosity” shall denote liquid fillers (at 100° C.) that have a kinematic viscosity at 100° C. in the range of from 1 to 45,000 centistokes (“cSt”). In various embodiments, the low-viscosity filler can have a viscosity at 100° C. in the range of from 4 to 30,000 cSt, from 4 to 15,000 cSt, from 4 to 2,000 cSt, from 4 to 1,700 cSt, or from 4 to 250 cSt. Specific examples of such materials include paraffinic oils, such as the SUNPAR™ grades (available from Sunoco Corp.); vegetable oils, such as soybean oil, poly-alpha olefin (“PAO”) fluids, such as the DURASYN™ grades (available from Ineos Corp.); and polybutenes, such as the INDOPOL™ grades (available from Ineos Corp.).

Other suitable materials are formulated compounds such as those typically used in filling and flooding telecommunication cables. An example of a filling compound used in buffer tube fiber optic telecommunication cables is a thixotropic gel, disclosed in U.S. Pat. No. 5,505,773 and composed of polybutylene, fumed silica, and polyethylene wax. A typical flooding compound is disclosed in U.S. Pat. No. 4,724,277 and is composed of a mixture of microcrystalline wax, a polyethylene, and a rubber. Examples of such materials include those commercially available from Sonneborn LLC, Soltex Corp, H&R ChemPharm (UK) Ltd, and MasterChem Solutions; as well as compounds based on high melt index Polyolefin Elastomers such as those disclosed in U.S. Provisional Patent Application Ser. Nos. 62/140,673 and 62/140,677. Other examples include compounds formulated with EASTOFLEX™ amorphous polyolefins, available from Eastman Chemical Company. Some cable filling/flooding compounds are engineered with viscosity exhibiting shear thinning profiles to enable pumping at room temperature without requiring additional heating.

TABLE 1 Typical viscosities of suitable low viscosity materials Kinematic Viscosity (cSt) (Typical Temperature Range) Material (° C.) Min. Max. Ref. Lubricating Oil (SAE Engine Oil) 100 4 25 1 Lubricating Oil (SAE Gear Oil) 100 7 1,700 1 Vegetable Oils 100 6 15 2-3 Polybutene 100 1 45,000 4 Sunpar Oil 100 3 31 5 Cable Flooding Compounds 120 200 250 6 150 170 7 [1] J. Sanders, Putting the Simple Back into Viscosity, White Paper, Lubrication Engineers Inc., 2011 [2] T. W. Ryan et al., The Effects of Vegetable Oil Properties on Injection and Combustion in Two Different Diesel Engines, Journal of the American Oil Chemists' Society 61, no. 10 (October 5): 1610-1619 [3] Noureddini H. et al., Viscosities of Vegetable Oils and Fatty Acids, Journal of the American Oil Chemists' Society 69, no. 12 (December 1): 1189-1191 [4] Indopol Polybutene Product Bulletin, Ineos Oligomers, Brochure No. PB1000, November 2009 [5] Sunoco Product Information, Sunpar Range, March 2013 [6] Telephone Flooding Compound FC 57 M, Product Data Sheet, Sonneborn Refined products, March 2012 [7] Cable Flooding Compounds (Soltex Flood 522), Soltex, March 2009

The microcapillaries in the peelable polymeric coatings can either be longitudinally continuous (or substantially continuous) or non-continuous along the length of the polymeric coating. As used in this embodiment, the term “substantially continuous” shall mean that the microcapillaries extend in an uninterrupted fashion for at least 90% of the length of the peelable polymeric coating. When longitudinally discontinuous, the microcapillaries can have any desired length. In various embodiments, the longitudinally discontinuous microcapillaries can have an average length ranging from 1 to about 100 cm, from 1 to 50 cm, from 1 to 20 cm, from 1 to 10 cm, or from 1 to 5 cm.

In various embodiments, the peelable polymeric coatings can comprise external indicia corresponding to the location of the microcapillaries. Such external indicia should enable a person working with the coated conductor to locate the points on the coating that enable the coating to be peeled. Incorporation of external indicia can be accomplished by any means known or hereafter discovered in the art. Examples of such indicia include, but are not limited to, printing, engraving, coloring, or embossing.

In one or more embodiments, the peelable polymeric coating can have a reduction in tensile strength of less than 50%, less than 45%, less than 40%, less than 35%, or less than 30% relative to an identical coating prepared from the same polymeric matrix material except not having microcapillaries. Additionally, the peelable polymeric coating can have a reduction in tensile strength in the range of from 10 to 50%, or from 20 to 45% relative to an identical coating prepared from the same polymeric matrix material except not having microcapillaries.

In various embodiments, the peelable polymeric coating can have a reduction in elongation-at-break of less than 30%, or less than 25% relative to an identical coating prepared from the same polymeric matrix material except not having microcapillaries. Reduction in elongation-at-break is determined by calculating the difference in elongation-at-break between the reference coating and the peelable coating, dividing that difference by the elongation-at-break of the reference coating, and multiplying by 100%. For example, if a reference coating has an elongation-at-break of 900%, and a peelable coating has an elongation-at-break of 800%, the reduction in elongation at break is (100/900)*100%, or 11.1%. Additionally, the peelable polymeric coating can have a reduction in elongation-at-break in the range of from 5 to 30%, or from 10 to 25% relative to an identical coating prepared from the same polymeric matrix material except not having microcapillaries.

In various embodiments, the peelable polymeric coating can have a reduction in tear strength of at least 5%, at least 10%, at least 25%, at least 50%, or at least 75% relative to an identical coating prepared from the same polymeric matrix material except not having microcapillaries. Additionally, the peelable polymeric coating can have a reduction in tear strength up to 90%, up to 85%, or up to 80% relative to an identical coating prepared from the same polymeric matrix material except not having microcapillaries.

Preparation of the peelable coatings can be accomplished by simple modifications of the above-described die assemblies to reduce the number of microcapillaries as desired. Such modifications are within the abilities of one having ordinary skill in the art.

Test Methods Density

Density is determined according to ASTM D 792.

Melt Index

Melt index, or 12, is measured in accordance with ASTM D 1238, condition 190° C./2.16 kg, and is reported in grams eluted per 10 minutes.

Tensile Strength and Elongation at Break

Measure tensile strength and elongation according to ASTM method D 638.

Tear Strength

The tear strength is measured as follows: 5.0-inch-long specimens are die cut from extruded tape samples and a 1.0-inch-long slit is made on each specimen. Tear testing is conducted on an Instron Model 4201 tester in the axial tape direction at 12″/min speed. Reported data are average values based on measurement of five specimens.

Materials

The following materials are employed in the Examples, below.

AXELERON™ GP C-0588 BK (“LDPE”) is a low-density polyethylene having a density of 0.932 g/cm³, a melt index (I₂) in the range of from 0.2 to 0.4 g/10 min., and containing carbon black in an amount ranging from 2.35 to 2.85 wt % (ASTM D1603). AXELERON™ GP C-0588 BK is commercially available from The Dow Chemical Company, Midland, Mich., USA.

AXELERON™ FO 6548 BK (“MDPE”) is a medium-density polyethylene having a density of 0.944 g/cm³, a melt index (I₂) in the range of from 0.6 to 0.9 g/10 min., and containing carbon black in an amount ranging from 2.35 to 2.85 wt % (ASTM D1603). AXELERON™ FO 6548 BK is commercially available from The Dow Chemical Company, Midland, Mich., USA.

ENGAGE™ 8200 is an ethylene/octene polyolefin elastomer having a density of 0.870 g/cm³ and a melt index of 5.0 g/10 min., which is commercially available from The Dow Chemical Company, Midland, Mich., USA.

Examples Sample Preparation Air-Filled Microcapillary Samples

Prepare four samples (S1-S4) using a tape-extrusion system consisting of a single-screw extruder (3.81-cm Killion extruder) fitted with a microcapillary die capable of handling a polymer melt and an air stream, as schematically depicted in FIG. 1. The die to be used in these Examples is described in detail in PCT Published Patent Application No. WO 2014/003761, specifically with respect to FIGS. 4A and 4A1, and the corresponding text of the written description, which is incorporated herein by reference. The die has 42 microcapillary nozzles, a width of 5 cm, and a die gap of 1.5 mm. Each microcapillary nozzle has an outer diameter of 0.38 mm and an inner diameter of 0.19 mm. The plant air is supplied by an air line with a flow meter, which is fully open prior to heating the machine to prevent blockage of the microcapillary nozzles by the backflow of polymer melt. In preparing the microcapillary sheets, first the extruder, gear pump, transfer lines, and die are heated to the operating temperatures with a “soak” time of about 30 minutes. Operating temperatures are shown in Table 2. As the polymer pellets pass through the extruder screw, the polymer becomes molten. The extruder screw feeds the polymer melt to the gear pump, which maintains a substantially constant flow of polymer melt towards the microcapillary die. Next, the polymer melt passes over the microcapillary nozzles and meets with streamlines of air flow, which maintain the size and shape of the microcapillary channels. Upon exiting the extrusion die, the extrudate is passed over a chill roll. Once the extrudate is quenched, it is taken by a nip roll. The air flow rate is carefully adjusted in such a way that the microcapillaries do not blow out but maintain reasonable microcapillary dimensions. The line speed is controlled by a nip roll in the rollstack. The sample compositions, their properties, and other process parameters are provided in Table 3, below.

TABLE 2 Temperature Profile of Microcapillary Extrusion Line for Air-Filled Microcapillary Sheets. Extruder Extruder Extruder Extruder Adaptor Transfer Screen Feed Die Zone 1 Zone 2 Zone 3 Zone 4 Zone Line Changer block Zone (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) 374 392 410 428 428 428 428 428 428 The resulting tapes are about 1.6 inches wide and approximately 50 mils thick, and have the following properties, shown in Table 3.

TABLE 3 Composition and Properties of Samples S1-S4 S1 S2 S3 S4 MDPE (wt %) 100 100 — — LDPE (wt %) — — 100 100 Air Flow Rate (mL/min) 20 40 20 40 Line Speed (ft/min) 6.6 7.2 6.0 6.0 Average Film Thickness (mm) 1.00 1.06 1.04 1.21 Average Film Width (cm) 4.1 4.1 4.2 4.2 Area Percentage of 27.5 35 22.5 31.2 Microcapillaries in the Film (%) Long Axis of a Microcapillary 718 769 722 804 (μm) Short Axis of a Microcapillary 389 504 355 519 (μm) Space between Two 263 210 264 196 Microcapillaries (μm) Film Surface to Inner Surface of 282 279 330 352 Microcapillary (μm)

Comparative Samples and Elastomer-Filled Microcapillary Sample

Prepare one Sample (S5) and two Comparative Sample (CS1 and CS2) using a tape-extrusion system consisting of two single-screw extruders (1.9-cm and 3.81-cm Killion extruders) fitted with a microcapillary die capable of handling two polymer melt streams. This line consists of a 3.81-cm Killion single-screw extruder to supply polymer melt for the matrix material and a 1.9-cm Killion single-screw extruder to supply polymer melt for the microcapillaries via a transfer line to the microcapillary die. The die to be used in these Examples is described in detail in PCT Published Patent Application No. WO 2014/003761, specifically with respect to FIGS. 4A and 4A1, and the corresponding text of the written description, which is incorporated herein by reference. The die has 42 microcapillary nozzles, a width of 5 cm, and a die gap of 1.5 mm. Each microcapillary nozzle has an outer diameter of 0.38 mm and an inner diameter of 0.19 mm.

Sample S5 and Comparative Samples CS1 and CS2 are prepared as follows. First, the extruders, gear pump, transfer lines, and die are heated to the operating temperatures with a “soak” time of about 30 minutes. The temperature profiles for the 3.81-cm and 1.9-cm Killion single-screw extruders are given in Table 4, below. Microcapillary polymer resins are charged into the hopper of the 1.9-cm Killion single-screw extruder, and the screw speed is turned up to the target value (30 rpm). As the polymer melt exits the microcapillary nozzles, the matrix polymer resins are filled into the hopper of 3.81-cm Killion single-screw extruder and the main extruder is turned on. The extruder screw of the 3.81-cm Killion single-screw extruder feeds the melt to a gear pump, which maintains a substantially constant flow of melt towards the microcapillary die. Then, the polymer melt from the 3.81-cm Killion single-screw extruder is divided into two streams, which meet with polymer strands from microcapillary nozzles. Upon exiting the extrusion die, the extrudate is cooled on a chill roll on a rollstack. Once the extrudate is quenched, it is taken by a nip roll. The line speed is controlled by a nip roll in the rollstack.

TABLE 4 Temperature Profiles of the 3.81-cm and 1.9-cm Killion Single-Screw Extruders Extruder Extruder Extruder Extruder Adaptor Transfer Screen Feed Die Zone 1 Zone 2 Zone 3 Zone 4 Zone Line Changer block Zone Extruders (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) (° F.) 3.81-cm 374 392 410 428 428 428 428 428 428 Extruder 1.9-cm 338 410 428 — — 428 — — — Extruder

The extrusion system is set up to supply two polymer melt streams: a first polymer (3.81-cm Killion extruder) to make a continuous matrix surrounding a second polymer (1.9-cm Killion extruder) shaped as microcapillaries embedded in the first polymer. The first polymer (matrix) of S5 is MDPE, and the second polymer (microcapillary) of S5 is ENGAGE™ 8200. For CS1, both the first and second polymers are MDPE. For CS2, both the first and second polymers are LDPE. The processing conditions and microcapillary dimension for S5, CS1, and CS2 are given in Table 5, below. Estimated from density measurements, S5 contains 18 weight percent of the microcapillary material (ENGAGE™ 8200).

TABLE 5 Processing Conditions and Microcapillary Dimensions for S1 and CS1 S5 CS1 CS2 Matrix Material MDPE MDPE LDPE Microcapillary Material ENGAGE ™ 8200 MDPE LDPE Screw Speed of 3.81-cm 15 15 15 Extruder (rpm) Screw Speed of 1.9-cm Extruder 30 30 30 (rpm) Line Speed (ft/min) 5 5 5 Average Film Thickness (mm) 1.30 1.05 1.1 Average Film Width (cm) 4.2 4.5 4.4 Area Percentage of 17.4 — — Microcapillaries in the Film (%) Long Axis of a Microcapillary 604 — — (μm) Short Axis of a Microcapillary 355 — — (μm) Space between Two 371 — — Microcapillaries (μm) Film Surface to Inner Surface of 354 — — Microcapillary (μm)

Example

Analyze each of CS1, CS2, and S1-S5 according to the Test Methods provided above. The results are provided in Table 6, below.

TABLE 6 Properties of CS1, CS2, and S1-S5 % Tensile Tear Strength Tear Reduction Tensile Strength Elongation Sample (lb/in.) vs. Control (psi) (%) MDPE-based Samples CS1 839.3 — 4,666 910 S1 197.3 76.5 3,168 807 S2 167.3 80.1 2,530 693 S5 413.4 50.7 3,388 857 LDPE-based Samples CS2 295.7 — 2,836 661 S3 128.1 56.7 2,203 523 S4 83.1 71.9 2,040 598

CS1 is a sample representing a solid tape made of commercial MDPE, which shows a tear strength of about 840 lb/in. and the typical tensile and elongation properties for this compound. S1 and S2 show the same compound extruded into a tape with air-filled microcapillaries. When torn in the axial direction along one of the capillaries, the tear strength is shown to be reduced by 76 and 80% respectively depending on the size of the microcapillaries. S5 shows that a sample having microcapillaries filled with a polyolefin elastomer (ENGAGE™ 8200) can also provide significant reduction in tear strength (about 51%).

CS2 is a sample representing a solid tape made of commercial LDPE, which shows a tear strength of about 296 lb/in. and the typical tensile and elongation properties for this compound. S3 and S4 are samples made using the LDPE compound with air-filled microcapillaries, showing tear strength reductions of about 57 and 72% respectively depending on the size of the microcapillaries.

It should be noted that all the inventive samples above are made with 42 microcapillaries. Such a construction has an effect on the overall tensile and elongation properties as shown by the data. As described earlier, however, only a limited number (e.g., 2 to 4) of microcapillaries placed around the jacket circumference would be needed to provide ease of tearing, while the rest of the jacket can remain unchanged for maximum mechanical protection of the cable. This would minimize the negative impact of the microcapillaries on the overall jacket mechanical properties. 

1. A coated conductor, comprising: (a) a conductor; and (b) a peelable polymeric coating surrounding at least a portion of said conductor, wherein said peelable polymeric coating comprises a polymeric matrix material and in the range of from 1 to 8 microcapillaries which extend substantially in the direction of elongation of said peelable polymeric coating, wherein said microcapillaries comprise a low-viscosity filler material.
 2. The coated conductor of claim 1, wherein said low-viscosity filler is selected from the group consisting of paraffinic oils, vegetable oils, poly-alpha olefin fluids, polybutenes, formulated cable flooding and filling compounds, and combinations of two or more thereof.
 3. The coated conductor of claim 1, wherein an aggregate of the space defined by said microcapillaries when viewed as a cross-section of the peelable polymeric coating taken orthogonal to the direction of elongation of said microcapillaries constitutes less than 20 area percent of the total area of said peelable polymeric coating cross-section.
 4. The coated conductor of claim 1, wherein said microcapillaries have an average diameter in the range of from 0.5 μm to 2,000 μm, wherein said microcapillaries have a cross-sectional shape selected from the group consisting of circular, rectangular, oval, star, diamond, triangular, square, pentagonal, hexagonal, octagonal, curvilinear, and combinations thereof, wherein said peelable polymeric coating has a thickness in the range of from 10 to 180 mils.
 5. The coated conductor of claim 1, wherein the ratio of the thickness of said peelable polymeric coating to the average diameter of said microcapillaries is in the range of from 2:1 to 400:1.
 6. The coated conductor of claim 1, wherein said peelable polymeric coating has a reduction in tensile strength of less than 50% relative to an identical coating prepared from the same matrix material except not having microcapillaries, wherein said peelable polymeric coating has a reduction in elongation-at-break of less than 30% relative to an identical coating prepared from the same matrix material except not having microcapillaries.
 7. The coated conductor of claim 1, wherein said polymeric matrix material comprises an ethylene-based polymer.
 8. The coated conductor of claim 1, wherein said peelable polymeric coating comprises external indicia corresponding to the internal location of said microcapillaries.
 9. The coated conductor of claim 1, wherein said microcapillaries are substantially longitudinally continuous along the length of said peelable polymeric coating.
 10. The coated conductor of claim 1, wherein said microcapillaries are longitudinally discontinuous along the length of said peelable polymeric coating. 